Inflators and methods of making inflators for safe transport and use with inflatable airbag cushions

Abstract

Inflators for safe transport and use with an inflatable airbag cushion and airbag systems include a diffuser comprising a first aperture and at least one vent aperture each disposed in a lateral sidewall of the diffuser. The first aperture and the at least one vent aperture are positioned to face in at least substantially opposite directions in the diffuser. A filter is positioned within the diffuser and includes an outer surface having a lateral extent less than a lateral extent of an inner surface of the lateral sidewall of the diffuser, resulting in a gap between the outer surface of the filter and the inner surface of the lateral sidewall of the diffuser. At least one reaction device is coupled to a longitudinal end of the diffuser. Methods of making such inflators are also included.

1 . An inflator for use with an inflatable airbag cushion system, comprising:
 a hollow body defining a diffusion chamber, the hollow body including:
 a first longitudinal end and an opposing second longitudinal end; 
 a first aperture disposed in a lateral sidewall of the hollow body; and 
 at least one vent aperture disposed in the lateral sidewall of the hollow body and positioned at least substantially opposite from the first aperture; 
   a filter positioned at least substantially within the diffusion chamber and forming a channel between an inner surface of the hollow body and an outer surface of the filter; and   a first reaction device coupled to one of the first longitudinal end or the second longitudinal end of the hollow body.   
     
     
         2 . The inflator of  claim 1 , wherein the first reaction device comprises:
 a first reaction housing defining a reaction chamber containing a quantity of gas generant; and   an initiator device coupled to the first reaction housing and in sufficient communication with the gas generant to initiate a reaction for producing a supply of inflation gas during deployment.   
     
     
         3 . The inflator of  claim 1 , further comprising a second reaction device coupled to the other of the first longitudinal end or the second longitudinal end of the hollow body, opposite from the first reaction device. 
     
     
         4 . The inflator of  claim 1 , further comprising a blank coupled to the other of the first longitudinal end or the second longitudinal end of the hollow body, opposite from the first reaction device, wherein the blank encloses the longitudinal end to which it is coupled. 
     
     
         5 . The inflator of  claim 1 , further comprising a plug disposed to at least substantially occlude the first aperture within the lateral sidewall of the hollow body, causing the previously thrust neutral inflator to become thrust positive. 
     
     
         6 . The inflator of  claim 1 , further comprising a plurality of mounting studs extending through respective stud apertures in the hollow body, each mounting stud including a stud head disposed in the channel between the inner surface of the hollow body and the outer surface of the filter. 
     
     
         7 . The inflator of  claim 6 , wherein each stud aperture is axially aligned with a respective vent aperture so that a mounting stud may be inserted through the respective stud aperture by means of the respective vent aperture. 
     
     
         8 . A thrust-neutral inflator adapted for use with an inflatable airbag system, comprising:
 a diffuser comprising a first aperture and at least one vent aperture each disposed in a lateral sidewall of the diffuser, wherein the first aperture and the at least one vent aperture are positioned to face in at least substantially opposite directions;   a filter positioned at least partially within the diffuser, the filter comprising an outer surface having a lateral extent less than a lateral extent of an inner surface of the lateral sidewall of the diffuser to form a gap between the outer surface of the filter and the inner surface of the lateral sidewall of the diffuser; and   a first reaction device coupled to a longitudinal end of the diffuser.   
     
     
         9 . The thrust-neutral inflator of  claim 8 , wherein the first aperture and the at least one vent aperture are positioned about 180° apart around a central longitudinal axis of the diffuser. 
     
     
         10 . The thrust-neutral inflator of  claim 8 , wherein the first reaction device comprises:
 a first reaction housing defining a reaction chamber that contains a quantity of gas generant; and   an initiator device coupled to the first reaction housing and positioned in sufficient communication with the gas generant to initiate a reaction for producing a supply of inflation gas during deployment.   
     
     
         11 . The thrust-neutral inflator of  claim 8 , further comprising a second reaction device coupled to another longitudinal end of the diffuser, opposite from the first reaction device. 
     
     
         12 . The thrust-neutral inflator of  claim 8 , further comprising a blank coupled to another longitudinal end of the diffuser, opposite from the first reaction device, wherein the blank at least substantially encloses the other longitudinal end to which it is coupled. 
     
     
         13 . The thrust-neutral inflator of  claim 8 , further comprising a plug disposed to enclose the first aperture within the lateral sidewall of the diffuser, causing the previously thrust neutral airbag cushion inflator to become thrust positive. 
     
     
         14 . The thrust-neutral inflator of  claim 8 , further comprising a plurality of mounting studs extending through respective stud apertures in the lateral sidewall of the diffuser, each mounting stud including a stud head disposed in the gap between the outer surface of the filter and the inner surface of the lateral sidewall of the diffuser. 
     
     
         15 . The thrust-neutral inflator of  claim 14 , wherein each stud aperture is axially aligned with a respective vent aperture so that a mounting stud may be inserted through the respective stud aperture by means of the respective vent aperture. 
     
     
         16 . A method of forming a thrust-neutral inflator adapted for use with an inflatable airbag cushion system, the method comprising:
 forming a first aperture in a lateral sidewall of a diffuser;   forming at least one vent aperture in the lateral sidewall of the diffuser, the at least one vent aperture being positioned to face in an opposite direction from the first aperture;   disposing a filter at least partially within the diffuser to form a channel between an outer surface of the filter and an inner surface of the lateral sidewall of the diffuser; and   coupling a first reaction device to a longitudinal end of the diffuser.   
     
     
         17 . The method of  claim 16 , wherein forming the at least one vent aperture in the lateral sidewall of the diffuser positioned to face in an opposite direction from the first aperture comprises forming the at least one vent aperture in the lateral sidewall of the diffuser about 180° apart from the first aperture. 
     
     
         18 . The method of  claim 16 , further comprising:
 coupling a second reaction device to another longitudinal end of the diffuser, opposite from the first reaction device.   
     
     
         19 . The method of  claim 16 , further comprising:
 disposing a plug within the first aperture to occlude the first aperture formed in the lateral sidewall of the diffuser.   
     
     
         20 . The method of  claim 16 , further comprising:
 positioning a plurality of mounting studs to extend through the lateral sidewall of the diffuser, wherein a stud head of each mounting stud is disposed in the channel between the outer surface of the filter and the inner surface of the lateral sidewall of the diffuser.   
     
     
         21 . The method of  claim 20 , wherein the at least one vent aperture is formed at least substantially axially aligned with at least one stud aperture formed in the lateral sidewall of the diffuser, and wherein positioning the plurality of mounting studs to extend through the lateral sidewall of the diffuser comprises:
 inserting each mounting stud into the diffuser through the at least one vent aperture; and   disposing each mounting stud through a respective stud aperture.   
     
     
         22 . The method of  claim 20 , wherein positioning the plurality of mounting studs to extend through the lateral sidewall of the diffuser comprises:
 inserting each mounting stud into the diffuser through a longitudinal end; and   disposing each mounting stud through a respective stud aperture formed in the lateral sidewall of the diffuser.